CN100418724C - Method and equipment for forming microstructure on polymer substrate - Google Patents
Method and equipment for forming microstructure on polymer substrate Download PDFInfo
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- CN100418724C CN100418724C CNB028167252A CN02816725A CN100418724C CN 100418724 C CN100418724 C CN 100418724C CN B028167252 A CNB028167252 A CN B028167252A CN 02816725 A CN02816725 A CN 02816725A CN 100418724 C CN100418724 C CN 100418724C
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Abstract
The present invention relates to a method and a device thereof for forming a microstructure (126) on the surface of polymeric web materials (12) so as to be used as an optical memory substrate. The polymeric web materials (12) are temporarily laminated on a hot pressing die (14) and then enter an extrusion zone (16) which is formed among the hot pressing die (14), a pressure roller (20) and a supporting roller (22) to form the microstructure (126), wherein the hot pressing die (14) can be heated through any suitable heating device (18) so as to melt and flow the surface of the polymeric web materials (12) and stabilize the surface before separation. The hot pressing die (14) can pass through the extrusion region (16) through the carrying of a supporting member (28) which comprises a supporting frame (114) which has endless belts (118, 128) and a plurality of rollers (30, 32, 34), and the endless belts (118, 128) and the rollers (30, 32, 34) are independent of a pressure device which is formed by the pressure roller (20) and the supporting roller (22). The pressure roller (20) and the supporting roller (22) are respectively and rotatively driven by drives (24, 26).
Description
Technical field
The present invention relates in general to the method and apparatus of making optical memory.More especially, the substrate that the present invention relates to use device without interruption or roll-to-roll system to be shaped and to be used for optical memory and to be used to make CD.
Background technology
For example CD (compact disk), CD-R, CD-RW; The common following manufacturing of optical memory dish of DVD (digital universal disc), DVD-R, DVD-ROM, DVD+RW, PD (phase change disk) and MO (magneto-optic disk) etc., promptly be shaped at first substrate and on substrate the deposition one or more thin layers.Common a series of groove and/or the pits that are arranged to concentric path or continuous helical line that are shaped of substrate that are used for optical memory.Groove and pit can be used as laser beam tracking, address information, timing, error correction, data etc.The substrate that is used for CD is usually by injection-molded shaping, and wherein melt polymer material is expelled in the dish type mould, and a surface of this mould has the patterned micro-structural that will duplicate.This patterned micro-structural provides by the interchangeable plug-in unit that is commonly referred to as pressing mold usually.Injection-molded process comprises the step of a series of accurate timing, and this step comprises close die, injects molten polymer, controllably reduces peak value injection pressure, cooling, shaping centre bore, opening mold and takes out replicating disk and relevant running channel.After molding process, the one or more protective layers of the dish common coating of substrate, bonding adhesive, ornament, label etc.
Although for example described injection molding process can provide the high-quality light memory disk, it has the birefringence and the flatness of acceptable level, and the dish speed of production is only in several seconds scope.About 60% of these times are used for molded step, and other times need be used for opening mold, taking-up dish and running channel and follow close die before next circulation beginning.In addition, now by using multiple novel ejection technique or only having obtained limited success with the trial that improves productivity ratio by use multi-cavity chamber mould.
Except lower than required productivity ratio, the injection-molded closed-loop path control that needs complexity at many parameters.For example, all molded and polymer temperature, forcing press clamping force, injection section and retention times have competition and often opposite effect for birefringence, flatness and the precision of replicated architecture.This should be noted that molded difficulty increases when the thickness of replicating disk reduces.For example do not need to use the special technique that increases the cross section, injection compression molding, punching out, " impacting molded " etc. of molding cavity at main injection stage under the situation of standard CD substrate of 1.2mm so be approximately at thickness, in order to satisfy the requirement of birefringence and flatness, the standard DVD substrate that thickness is approximately 0.6mm need adopt special technique.
The trend in future of optical memory product is towards thinner substrate and/or littler dish.By injection-molded these products of direct manufacturing may be unpractiaca.(promptly 5～8cm), the disturbance that the center cast causes can influence on the dish quality of inner line of rail for for example using minor diameter dish at PDA(Personal Digital Assistant) and digital electronic camera.Near the central cast gate of these disturbances and local eddy currents, shearing and mould compaction rate changes and is associated, and can cause local poor flatness and birefringence height.When minimum path diameter reduces, can make that these problems are serious.
In order to quicken productivity ratio, the method that many employing continuous web lining technologies are made optical memory has been proposed.These methods are based upon by paper web being passed between roller and the pressing mold so that forming on the theory of microstructure graph on the continuous material roll lining.
Up to now, put forward continuous web lining technology from type.These technologies comprise " online " and " off-line " method.On-line continuous paper web technology combines paper web extruding and microstructure graph shaping in same process, and off-line continuous web lining technology is carried out the paper web shaping on the paper web material of making in advance, and this paper web material is made on another production line.The purpose of online shaping be after paper web extruding and the paper web or the situation of heat under contact paper web with pressing mold.The example of Wiring technology comprise following patent described those: U.S. Patent number 5,137,661; 4,790,893; 5,368,789; 5,281,371; 5,460,766; 5,147,592 and 5,075,060, these patents are hereby expressly incorporated by reference.What paper web extruding and paper web were shaped not only is engaged in occupation of making CD but also the occupation of being engaged in the paper web extruding in conjunction with needing to coil manufacturer.This makes that whole system is the process of high complexity, does not especially wish so local.In addition, because dish manufacturer does not have the large-scale production of plastics paper web manufacturer, can be higher than the cost of offline process in the unit cost of Wiring technology formed thereby dish.Therefore, the offline process that the present invention proposes not only provides and improves output, reduces cost and complexity and the chance that shortens start-up time, but also has increased process flexibility.
It is the United States Patent (USP) 6 that is entitled as " Directed Energy Assisted In Vacuo MicroEmbossing " that Kime proposes that use is used to make the method that the paper web at Wiring technology of optical memory is shaped, 007,888, this patent was submitted on December 28th, 1999, and its disclosure content is hereby expressly incorporated by reference.Kime discloses a kind of continuously manufacturing that uses the auxiliary minute-pressure line of DIRECT ENERGY.This patent describe a kind of before paper web and pressing mold press together by compression roller the DIRECT ENERGY source of heating paper web material and pressing mold.
Although think that Kime instructs finely, when the more and more higher data set of shaping density, many factors that can not occur usually can appear.For example, the present invention has been found that the inevitable variation that exists web surface texture and paper web thickness, and this variation can with the interference of duplicating of tiny micro-structural.These variations cause uneven contact pressure between paper web and the pressing mold partially.So that in the process of formation micro-structural, simply increase fully head it off of average contact pressure in softening paper web, but this is owing to elastic recoil in the paper web material after the too high contact pressure build-up of pressure removal causes the distortion pattern on surface.The relative motion of pressing mold paper web can cause " smearing ".Spread upon the shape of deformation data path on the micro-ratio and/or pit.These distortion can and also can increase the read error rate with the tracking interference.Therefore, need a kind of method and/or equipment, the negative effect that its variation that adapts to web surface texture and paper web thickness causes.
For the micro-structural of replica stamper exactly, attempted that pressing mold and paper web are kept sufficiently long and contacted, make the polymer retraction and the substrate cooling of displacement.It is worthless method that but the present invention finds simply to increase time of contact, and this is owing to increased warp then.Be appreciated that the dish of warp produces reads to cross-examine topic significantly.For can writing dish, the problem that warp is relevant becomes bigger problem, wherein can reduce recording quality and increase the weight of the negative effect of warp during reading.Therefore, need a kind of continuation method and/or equipment of making optical memory, this equipment is at substrate shaping restriction warp.
Summary of the invention
Consider above factor, the invention provides the method and/or the equipment of a kind of continuous manufacturing optical memory or optical memory substrate and/or CD, it comprises that supplying material web expects on the substrate former.
In one aspect of the invention, provide a kind of by the method for the thermal force on the restriction paper web with the shaped polymer material.
In another aspect of this invention, provide a kind of method of passing through the lip-deep micro-structural of melt-shaping material roll lining with the shaped polymer material.
In another aspect of this invention, provide a kind of pressing mold that adopts eddy-current heating on the surface of polymeric material, to form the method for micro-structural.
In another aspect of this invention, a kind of method that forms micro-structural in the following manner on the polymeric material web surface is provided, promptly provides to have the surface aggregate thing material roll lining that has glidant and adopt the pressing mold of heating on surface of polymer material, to form micro-structural.
In another aspect of this invention, the method that provides a kind of manufacturing to be used for the pressing mold of continuous web lining forming process, this method are included in transferable pattern are provided on the pressing mold; Curved stamp also increases the thickness of pressing mold after the pressing mold bending.
In another aspect of this invention, provide a kind of by being provided at the method that pressing mold that the paper web shaping has limited thermal expansion comes the shaped polymer material.In aspect it is preferred, pressing mold has the thermal coefficient of expansion lower than nickel.Its another preferred aspect in, pressing mold has limited variations in temperature with the paper web period of contact.
In another aspect of this invention, provide a kind of equipment that is used for forming micro-structural on the surface of polymeric material paper web, this equipment comprises: the paper web feeding mechanism; Be used for the device that paper web is shaped, be used for a pair of compression roller that device that paper web is shaped has the crush-zone that pressing mold and formation is communicated with the paper web feeding mechanism, this pressing mold passes crush-zone by carrying from the supporting member carrying that compression roller is dismantled, described supporting member comprises mutual at least two endless belt that are arranged that axially divide, described pressing mold is positioned at the supporting member between described two endless belt, the part of wherein said pressing mold graft polymerization thing material roll lining in crush-zone.
In another aspect of this invention, provide a kind of equipment that is used to make optical memory, this equipment comprises: the paper web feeding mechanism; The pressing mold that is used for the shaped polymer material, this pressing mold are carried on the loop and with the paper web feeding mechanism and are communicated with; Be used for after being shaped, cutting off the paper web cutter of paper web material; And the gatherer of collecting the portion's section after the cut-out of paper web material.
In the present invention on the other hand, provide a kind of in the method that is used for forming on the surface of polymer material of optical memory micro-structural, this method may further comprise the steps: provide to have the reel that can remove than the polymerization paper web material of soft material layer; And adopt the pressing mold shaping paper web of heating, and the polymeric material of rolling forming once more.
In another aspect of this invention, provide a kind of equipment that is used to make optical memory, this equipment comprises: the paper web feeding mechanism; The pressing mold that is used for the shaped polymer material, this pressing mold are carried on the loop and with the paper web feeding mechanism and are communicated with; Be used for after being shaped, cutting off the paper web cutter of paper web material; And the accumulator of collecting the portion's section after the cut-out of paper web material; Be used for after being shaped, covering the station of covering of paper web segments of material; And at least one is applied to film the coating bringing device on the paper web segments of material after covering.
In another aspect of this invention, provide a kind of paper web that is used for making in continuous web lining technology optical memory to block the station, it comprises: the platform that is used to support the paper web segments of material of shaping; Be used on the punch die path, aiming at a plurality of optical alignment sensors of shaping supporting material pattern and being used to cut off the punch die that is bearing in the paper web on the platform.
In another aspect of this invention, provide a kind of method of the polymeric material be used to make optical memory of being shaped in the following manner, promptly provide the crush-zone that enough is fit to, so that the variation of consideration web surface and thickness.
In another aspect of this invention, provide a kind of in the method that is used for forming on the polymeric material of optical memory micro-structural, this method may further comprise the steps: the polymeric material paper web is provided; The pressing mold of heating is provided; And between one group of compression roller the pressing mold and the substrate of pressurized, heated, wherein at least one compression roller has submissive outer surface, this surface has 80 Shore D or littler hardness.
In another aspect of this invention, a kind of system that makes the optical memory dish is provided, and this system comprises one or more with lower device: coating bringing device, paper web shearing device, casket boxlike collecting apparatus, paper web protractor, pick-up roller and can make finished product optical memory dish or the miscellaneous part of semi-finished product dish.
In another aspect of this invention, provide a kind of by before coating, covering the paper web segments of material so that the optical memory substrate of embossing is carried out the method for coating.
Description of drawings
In order to help to understand the different aspect of the present invention and various embodiments thereof, carry out reference for accompanying drawing now, wherein identical reference number is represented identical parts.Accompanying drawing represents with example only, and should not be used for limiting the present invention.
Fig. 1 is according to the present invention's be used to be shaped perspective view of equipment of paper web material of optical memory;
Fig. 2 is according to the present invention's be used to be shaped perspective view of another equipment of paper web material;
Fig. 3 is used for the diagram of the time of web surface melt-shaping to temperature curve according to the present invention;
Fig. 4 is according to the present invention's be used to be shaped side plan view of equipment of paper web material;
Fig. 5 is the side view that is used for continuous web lining optical memory production line according to the present invention;
Fig. 6 is according to the side view of the present invention for the system of optical memory backing coating;
Fig. 7 is the side view that is used for processing at last the system of optical memory according to the present invention;
Fig. 8 is the perspective view that is used for processing at last the system that optical memory makes according to the present invention;
Fig. 9 is the side view that is used to keep the system of paper web material according to the present invention;
Figure 10 is the side view that is used for the system of optical memory manufacturing according to the present invention;
Figure 11 is achieved in accordance with the invention by the top plan view of the system of covering last processing optical memory;
Figure 12 is the side view that carries out the system of coating according to the present invention for the paper web material;
Figure 13 is according to the stamper surface after the embossing of the present invention and the perspective view of web surface.
The specific embodiment
Carry out detailed reference for different aspect of the present invention and a plurality of embodiment now.
With reference now to Fig. 1,, its expression is used for the be shaped device of optical memory according to the present invention.This device comprises the paper web feeding mechanism or abbreviates the paper web path of paper web supply (not shown), transport of web material material 12 as and be arranged in paper web former in the paper web path.Paper web former 10 comprises pressing mold 14.Pressing mold is loaded with the micro structured pattern of the paper web that is used to be shaped.Pressing mold also can be heated by any suitable heater 18 heating and/or by drum or roller 22 with the pressing mold thermo-contact by supporting member 28 carryings.
Pressing mold is to be suitable for any instrument of leaving a trace on paper web material or optical memory substrate.Although pressing mold can have Any shape among the embodiment can selecting, for example oblate dish, ellipse, rectangle, triangle, irregularly shaped etc., pressing mold is dish type embossing instrument preferably.Pressing mold preferably has the small structure of making micro-structural on the optical memory substrate, for example groove and/or pit.The width of small structure, length and the degree of depth can be from greater than several microns to 0.01 micron or littler scopes.Figure 13 represents that the web surface that has the stamper surface of small structure and adopted the hot-die embossing is so that be combined in small structure the lip-deep AFM enlarged perspective of optical property paper web material.
Pressing mold is preferably made by rigid material, and this material can be heated to the peak value treatment temperature and remain on the ability that forms micro-structural on the paper web material simultaneously and be convenient to transfer energy to the ability on the interface between pressing mold and the polymeric material paper web when contact.Representational die material comprises nickel, chromium, cobalt, copper, iron, zinc etc., and the alloy of these materials.Pressing mold can comprise homogenous material or comprise a plurality of layers of same material or a plurality of layers of different materials.Pressing mold preferably includes the thick plate of material of 0.1～1.0mm, and more preferably comprises the plate of material that about 0.3mm ± 0.1mm is thick.As shown in Figure 1, pressing mold is flat.Understand equally and can select among the embodiment that pressing mold can be crooked.Crooked pressing mold makes pressing mold be convenient to carry on crooked route, and for example on the closed circuit of Guing, this is particularly useful for continuous processing.
In a preferred embodiment of the invention, preferably be shaped crooked pressing mold so that reduce the oval logo distortion.Have been found that with the concora crush mould bend to simply carrier or the drum shape can cause ovalizing deflection along curvature direction.Oval degree relevant with radius of curvature (for example, the radius of drum or transport path) and the thickness of pressing mold when bending are relevant.Find that equally also stretching, compression and/or elastic displacement paper web material cause the pattern deformation that must compensate.Useful pressing mold preferably has micro structured pattern, and it carries out The optimal compensation to distortion, makes pressing mold be suitable for being used for making the optical memory dish.Can The optimal compensation the curved stamp of distortion can be by suitable method manufacturing, for example by original shapes that changes pattern and the pattern that then on curved stamp, is shaped change.But in order to utilize the existing manufacturing system of making the concora crush mould, curved stamp is preferably also followed curved stamp by the micro-structural of shaping The optimal compensation on thin peaceful pressing mold and is made.After the pressing mold bending, the thickness of pressing mold increases so that make curved stamp have desired thickness.By bending and then increase the thickness of curved stamp, when using crooked carrier, pressing mold can be shaped so that preferably that pattern is out of shape optimization in advance, satisfies required heat and mechanical requirement simultaneously.For example, the structure graph of The optimal compensation is formed on the workpiece of relative thin (for example thickness is 0.1mm or littler).The instrument of relative thin then bends to required radius of curvature (for example 1～10 inch and more preferably 1～5 inch), and then is increased to required pressing mold thickness.The thickness of curved stamp can increase by any proper method, for example plating, bonding, welding, coating etc.Final pressing mold thickness is 0.2mm or bigger and more preferably about 0.3mm preferably.Pressing mold thickness is preferably in the pressing mold rear portion to be increased, and for example increases thickness on the sidepiece relative with micro-structural one side.Workpiece is configured as crooked carrier when its relative thin shape directly reduces the undesirable flexural deformation on the patterned side of stamper surface.On the pressing mold rear surface of prebending, add feasible machinery of material and hot property change subsequently and do not relate to excessive flexural deformation.In addition, be configured as under the situation about using with crooked carrier at pressing mold, hierarchy can provide other advantage in addition, for example reduces the distortion of pressing mold when heating and cooling, perhaps by changing blank side so that influence the lubricity at pressing mold/drum interface, as following described in more detail.
Have been found that and " smearing " owing to the different motion between pressing mold and the paper web produces pattern during the embossing.By being used to make the continuous web lining technology of optical memory, the present invention overcomes these problems, for example smears, and this comprises and is suitable for reducing pressing mold/paper web paper web former of change in size at the interface.Although simple nickel pressing mold can engage one or more embodiment of the present invention and use, have been found that simple nickel pressing mold does not need to have the optimal heat expansion/contraction characteristics.In addition, be delivered to from pressing mold can be influential for the contraction of pressing mold on the miscellaneous part of paper web former for heat.Therefore, preferred paper web former is in the contraction that provides pressing mold to be restricted with the paper web period of contact.In its preferred embodiment, at the paper web period of contact, the paper web former is suitable for providing less than 0.5% pressing mold and shrinks, more preferably less than 0.1%, and more preferably less than 0.01%.
In its preferred embodiment, by being provided, following pressing mold limits the pressing mold change in size, i.e. and the thermal expansion of pressing mold (and shrink) coefficient roughly is complementary with the thermal response at pressing mold/paper web interface.In some cases, particularly when very hot pressing mold contacted the forcing press of cool paper web or cold, contact can cause the quick cooling of hot-die and shrink.Shrink and make pattern deformation produce too greatly.By adjusting the thermal expansion performance of pressing mold, when the contact pressing mold, can reduce the differential of pressing mold/paper web, so that improve the shaping of pattern.According to its preferred embodiment, pressing mold has the thermal contraction less than the thermal contraction of simple nickel or traditional nickel pressing mold.When the contact paper web, thermal expansion is preferably less than 1%, more preferably less than 0.1% and more preferably less than 0.01%.Provide suitable means can reduce thermal expansion and/or contraction, for example by making pressing mold or pressing mold is formed sandwich construction etc. by the material of low thermal coefficient of expansion.By making pressing mold by alloy, pottery or the different materials that the pressing mold coating has a low thermal coefficient of expansion being reduced thermal expansion.For example, by making pressing mold with another metal, metal alloy or ceramic coating traditional nickel pressing mold with low thermal coefficient of expansion.By selecting to have the material of low thermal coefficient of expansion, a kind of pressing mold can be provided, this pressing mold does not have the relative contraction that can measure during the contact paper web.
In its another embodiment, the pressing mold change in size can by restriction from pressing mold to the paper web former or paper web or above both heat loss reduce the pressing mold change in size.Heat loss can limit in many ways: the biasing heat is provided on the pressing mold backing roll; With pressing mold and part of pressure machine insulation; And reduce the time of contact of pressing mold and paper web.Especially when pressing mold is independent of forcing press or backing roll and heats, enter backing roll to cause the contraction of pressing mold from the heat of pressing mold.By the biasing heat is provided on the pressing mold backing roll, can be restricted so that reduce the thermal contraction of mask from the heat of pressing mold transmission.As selecting or additional, pressing mold can with the backing roll heat insulation.Pressing mold can with backing roll by any suitable mode heat insulation, for example coating insulation thing on the pressing mold, on backing roll coating insulation thing etc.Preferably the heat loss from pressing mold to the pressing mold backing roll is less than 50%, more preferably less than 10%, and more preferably less than 1%.
Have been found that by the pressing mold that reduces to heat and the time of contact between the paper web, can realize reducing of change in size by the heat loss of restriction from the pressing mold main body.Mould temperature and pressing mold body temperature reduce preferably 50 ℃ or littler, be more preferably 25 ℃ or littler and be more preferably 10 ℃ or littler.Reduce to realize by increasing paper web speed and/or increasing the loop speeds of carrying pressing mold time of contact.But, advantageously when gathering way, also increased heat by pressing mold carrying, so that carry enough energy, thus melt-flow web surface as required.Paper web is preferably in length with vertical contact the (the paper web direction of motion) of pressing mold and all lacks on the time in crush-zone.Paper web is preferably with 3～30 inches speed conveying each second.Be preferably 300 milliseconds or littler time of contact between pressing mold and the paper web, and more preferably 20 milliseconds or littler.Be preferably 10 milliseconds or littler time of contact, but be preferably greater than 0.5 millisecond.When pressing mold and paper web forced together in crush-zone, vertically the length of contact was preferably 20mm or littler, more preferably 5mm or littler especially.By contact (for example length and/or the time) of restriction paper web and pressing mold, can realize the substrate warp that reduces.
Pressing mold can be by any proper device carrying to pass through crush-zone.Refer again to Fig. 1, pressing mold 14 passes through crush-zone 16 by supporting member 28 carryings.Supporting member can be paper web, sheet material, chain, band or pallet, " runner structure ", support, endless belt, track, drum, roller etc.Supporting member 28 is preferably carried pressing mold 14 closed-loop path by crush-zone 16 repeatedly.As shown in Figure 1, supporting member 28 is flat sheet materials.In alternate embodiments, for example shown in Fig. 2 and 4, supporting member 28 can be a support.
Pressing mold can be pressed against on the paper web by any suitable forcing press or pressue device.The device that is used to pressurize is one group of roller preferably, this roller shaping clamping point or holder.Forcing press preferably is delivered to pressing mold/paper web contact area with 500PLI (poundage of every linear inch) or littler pressure.Squeeze pressure is preferably in 50PLI in the scope of 300PLI.
Shown in Fig. 1,2 and 4, pressure roll 20 and backing roll 22 are by being used for pressing mold and the coarctate crush-zone 16 of paper web.Especially when pressing mold and paper web forced together by the round pressure machine that for example rouses, vertically the length of contact was preferably 20mm or littler, more preferably 5mm or littler and 1～2mm more preferably.Drum or roller that pressure roll 20 and backing roll 22 are preferably made by rigid material, this material for example are metal, alloy, pottery etc.Pressure roll 20 and backing roll 22 preferably have smooth finish surface.In a preferred embodiment, pressure roll 20 and a kind of material of backing roll 22 coatings, this material are chosen to influence the time/temperature curve (as mentioned above) at pressing mold/paper web interface and/or influence the lubricity at pressing mold/drum interface and/or flexible surface (as described below) is provided.When should preventing to contact pressing mold, the characteristic of backing roll produces fragment.Representational coating material comprises the polytetrafluoroethylene (PTFE) filled matrix of chromium, cobalt, nickel, iron, steel, stainless steel, molybdenum, titanium, zirconium, zirconia, silicon nitride, titanium nitride, diamond synthesis (DLC), polytetrafluoroethylene (PTFE) or described or similar material.Pressure roll 20 and backing roll 22 are preferably rotating.Roller can freely roll or rotate by one or more drivers 24 and 26.Driver 24 and 26 is preferably separate.If backing roll 22 with the bias temperature heating, is preferably operated under the situation that the peak value treatment temperature that realizes at the paper web/pressing mold interface side place than pressing mold 14 is low.By controlling the temperature of backing roll energetically,, can improve duplicating of micro-structural by limiting the heat that pressing mold is delivered to backing roll.
Adopt the method for optimizing of pressing mold and one group of compression roller shaping paper web to comprise: to offset downward paper web pressing mold flexural deformation and reduce squeeze pressure and offset paper web laterally or the paper web movement and deformation by increasing squeeze pressure, make pressing mold flexural deformation and paper web stretcher strain balance.For example the compression roller of 55 Shore D hardness with have curved stamp 8 " extruding drum uses.By 600 and 900lbs between change extruding force, can be in paper web balance ovality laterally and between the paper web downward direction, so that improve pattern quality.
Although the equipment of Pi Luing can have in all types of shaping paper web materials widely and to use here, the paper web material preferably has the polymeric material of the suitable optics, machinery and the hot property that are used to make the optical memory dish.Preferably, the paper web material is the thermoplastic polymer, for example polycarbonate, polymethylene acrylate, polyolefin, polyester, polyvinyl chloride, polysulfones, fibrous matter etc.The paper web material preferably has the refractive index that is applicable to the optical memory dish (for example 1.45～1.65).According to required application, the preferably about 0.05mm of paper web thickness～about 1.2mm.Preferably for duplicate one, two, three, four or a plurality of pattern on paper web, paper web 12 should be enough wide.The paper web material can contain one or more additives, for example antioxidant, UV absorbent, UV stabilizing agent, fluorescence or absorbing dye, antisatic additive, interleaving agent, filler, plasticizer, softening agent, surperficial glidant etc.The paper web material is " off-line " reel of making in advance preferably, and this reel can be fed in the system at ambient temperature.Paper web material with the reel form is fed in the system at ambient temperature, makes that process flexibility and efficient are bigger.
In order to form impression, before the contact paper web, pressing mold heats by heater.Heater can be any suitable heater, for example DIRECT ENERGY source, eddy-current heating source, conduction heating source, radiant heating source etc., or any combining form or equivalents.Pressing mold heats best separating with other elements of system that comprise clamping element, paper web, roller etc.Pressing mold heats before being preferably in and being carried to crush-zone.Preferably, also heating of supporting drum.
Heating preferably provides by load coil, and this coil produces the direct resistance heated of pressing mold.Load coil is preferably made by conductive material, for example copper, aluminium, silver etc.Load coil can comprise a series of formed conductors, and this conductor is connected on the suitable energy source.Load coil preferably passes through water cooling.Load coil is preferably placed near pressing mold so that have a resistance heating when the excitation load coil.Load coil preferably is placed in the 1mm～50mm scope of pressing mold.When pressing mold heated by load coil, pressing mold can be elevated to the temperature that is enough to melt web surface.Size by adjusting induction coil and geometry, the material by suitable selection pressing mold and change pressing mold and induction coil between distance can select the size and the uniformity that are coupled for pressing mold.Shown in Fig. 1,2 and 4, induction coil 18 is arranged in the upstream of replication region and the path of close pressing mold.
During embossing, the annealing of the subsurface of excessive contraction and/or paper web material can cause the paper web warp.Even a spot of warp of substrate also has problem for the optical memory device.The present invention considers that a plurality of methods reduce the possibility of warp.These methods comprise following one or more method: when paper web is neutralized mould/paper web interface temperature and time relation by the crush-zone time control, shorten the degree of depth that entire process time and/or the heating of restriction paper web are higher than Tg under the temperature that is higher than glass transition temperature Tg.By changing paper web warp angle and/or can reducing the paper web warp in both sides heating paper web in addition.Each of these methods can be used alone or in combination so that improve the duplicate pattern-forming and reduce warp.
According to the present invention, provide a kind of method by melt-flow web surface shaping polymerization paper web substrate.It is that heating paper web material surface becomes melt, makes its displacement and follows stable method that melt-flow is shaped.Can notice, be different from traditional compression stress relaxation method with the shaped polymer substrate by the interface surface melt-flow.In melt-flow, when pressing mold impacted on paper web, web surface was heated to the degree of material fusing and local flow.Material displacement and local flow combine and make web surface be consistent with microstructure graph on the pressing mold fast with exactly.Before separating pressing mold, make paper web stable.As a comparison, the compression stress relaxation method is in a period of time and be lower than use force deformation and displacement material under fusing or the temperature below the flowing temperature, so that the stress by producing in the lax paper web of compression stress.Replace the compression stress relaxation method by using melt-flow to be shaped, shorten the pattern-forming required time greatly so that the heating of restriction paper web main body.
In the preferred embodiment of melt-flow manufacturing process, stamper surface be arranged on melt-flow temperature (Tf) or more than.Temporary transient rising pressing mold/paper web interface temperature is not configured as the shape of the micro-structural of pressing mold fast to Tf or the above web surface that makes stress.Though pressing mold/paper web interface enough heat should too hotly not make the whole cross section of paper web melt so that cause the web surface melt-flow.Paper web preferably arrives the 0.2mm or the littler degree of depth downwards from the interface surface melt-flow, more preferably arrives the 0.1mm or the littler degree of depth, more preferably arrives the 0.05mm or the littler degree of depth, most preferably to the 1 μ m or the littler degree of depth.To handle heat penetration and be restricted to minimum,, can reduce the displacement and the annealing of material subsurface of subsurface like this, so that reduce distortion and warp up to the degree of depth of the structure that will be shaped.
Melt-flow time/temperature curve can be provided in many ways, this comprises pressing mold peak temperature and pressing mold hot property balance, adjust the initial temperature and the thermal response of paper web, the initial temperature at adjustment pressing mold/paper web interface and thermal response and/or change form the hot property of the roller of crush-zone.Fig. 3 represents the time/temperature curve according to the method for the melt-flow shaping of the preferred embodiment of the present invention.As shown in the figure, the temperature of web surface (y-axle) obtained afterwards in a period of time (x-axle) during embossing.In time of contact, the temperature of web surface from tilt to rise near environment or the Tcold (a figure point A) Tf (a figure point B) or above and then (fast) cool off in case before pressing mold and paper web are separated stable pattern.As selection, can be heated to environment temperature in advance or even be higher than Tg in pressing mold and paper web before paper web contacts.Preferably the web surface temperature drops to Tf or following (figure point C represents) before pressing mold and paper web are separated.
The following interface temperature of melt-flow temperature (for example less than Tf temperature) that pressing mold is preferably in paper web separates with paper web down.Usually should be noted that the interface cooling velocity can be by many condition influence, it comprises: be transmitted to the heat in the paper web, the hot property at paper web/pressing mold interface, provides one or more insulating barriers and effectively interface temperature control at the thermal conductivity of pressing mold.Pressing mold is preferably under the temperature that is higher than glass transition temperature Tg and separates.Because the shaping stress relevant with melt-shaping, after separating with pressing mold, the treatment surface of paper web can keep its micro-structural and continue cooling.
Although do not wish by theory, polymer response displacement force relates to viscosity composition and elastic component.Under Tf, the viscosity composition is main, and under Tcold (being lower than the temperature of Tg), elastic component is main.More than Tg (glass transition temperature), conversion appears, and wherein the increase of free space makes the molecular motion of rotation or translation occur.Thisly freely make a molecular motion surpass another molecule, it is main to cause viscous behavior to become.Need reduce stress significantly before separately at pressing mold at Ts or Tsoft (be lower than Tf but be higher than the temperature of Tg) lower corrugated polymeric material.As a comparison, a plurality of embodiment of the present invention consider at Tf or above temperatures line dish substrate, and before separately pressing mold/paper web laminate are cooled to below the Tf, but do not need to be lower than Tg.Arrive the optimum temperature point in the different embodiments of the invention and make that the micro-structural in the paper web is enough stable so that keep its shape after separately, avoid shrinking the distortion of relevant both macro and micro simultaneously with pressing mold.By providing the low viscosity interface at the pressing mold place, melt-shaping method of the present invention is intended to eliminate the restriction of slack time of relevant with traditional " hot pressing line " polymer.By profiled surface again, melt-shaping has also improved the mismachining tolerance of paper web thickness and texture variations.Melt-shaping also can utilize the surface activity of increase and stable again fast before pressing mold/paper web is separated.By the time/temperature curve at control pressing mold/paper web interface, the micro-structural on the pressing mold can be transferred on the paper web, and reduce for example littlely to smear, the defective of path warpage and warp.By the short time/other advantage that the high-temperature curve draws is that restriction enters the heat penetration in the paper web material.The heat leak that is restricted helps to reduce the subsurface annealing of polymer, and annealing then is the principal element of warp.Flashmelt is shaped and can reduces to be delivered to the overall thermal load of paper web.The thermal force that reduces can reduce heat penetration.Can reduce evenly heat simultaneously by the shape of adjustment time/temperature curve exposes so that realize high peak temperature on this surface, cooling fast subsequently, because the unstability of some polymer under high peak temperature causes this method in fact to be restricted.
Although can obtain the temperature/time graph of wide range by suitable selection material, too high peak temperature is undesirable all the time.Have been found that the overall physical properties that does not reduce the paper web polymer if can temporarily reduce the difference between Tf and the Tg, can more easily provide melt-flow to be shaped.The applicant has been found that and is using glidant can reduce required melt-flow shaping peak temperature before the melt-shaping on web surface selectively, and do not reduce the overall physical properties of paper web polymer.Do not have superheated adverse consequences for the mobile preferably dynamic property that obtains to increase, have been found that to use and add in web surface or the surf zone, so that temporarily increase the additive of mobile performance.
The paper web material preferably is provided with glidant.Glidant can be any material or the synthetic that is added in the paper web, and it provides the mobile performance of increase for basic paper web material under the situation of melt-flow.Glidant preferably reduces the material of melt surface flowing temperature effectively and/or increases the material of surface cool speed.Glidant preferably is provided with enough amounts, so that in the dynamic viscosity to the low paper web of fixed temperature decline.Be preferably in the glidant that 0.1～1.0% percentage by weight is provided in the web surface zone.Therefore, the paper web material preferably has enough at least glidants, so that reduce Tf, thereby is lower than dry type or does not have the record value of the material of glidant, and preferably add q.s, makes the rated peak treatment temperature reduce by 5%～50%.By the glidant of q.s is provided,, thereby make the micro-structural of improved optical memory quality by melt-shaping so that adjust the melt flow characteristics of paper web.
In the certain depth that glidant preferably is provided on the web surface or web surface is interior.Glidant is preferably disposed on the constructional depth that will make or only is lower than the structure that will make.Glidant is preferably disposed on the degree of depth of 0.003 μ m at least.Glidant can be provided with on the whole cross section of paper web, but preferably at least to top 50% or littler, more preferably arrives top 10% or littler.The glidant preferably degree of depth from this surface to 10 μ m is provided with, and more preferably is provided with from the surface to the degree of depth of 3 μ m.In advantageous applications, the 1.5 μ m that have only surf zone to begin have glidant.
Have been found that water is useful especially glidant.Have been found that not only water is effective glidant, and by cooling off web surface effectively so that stop the continuous heat that transmits from pressing mold, water can advantageously change paper web/pressing mold time/temperature curve at the interface.In addition, be sure of be the high heat of water evaporation help pressing mold/paper web at the interface fast cooling so that reduce pattern stabilization time.Traditionally, the water that is present in during embossing in the paper web material has very large problem, and this is because the water of holding back in the paper web can evaporate and produce bubble.These bubbles are formed between paper web and the pressing mold at the interface usually, produce recessed recess in web surface.These bubbles reduce the optical property of final products then.For the problem of water typical solution be by dry paper web with by removing moisture content in relative low temperature (being lower than Tg) time processing paper web.The applicant finds that the water that exists in the web surface during the melt-shaping is favourable, and this is because the suitable water yield not only can be improved the quality of transferring to the micro-structural on the paper web, but also can realize under the situation of shapeless steam bubble.By providing short processing time and shallow heat penetration can prevent to have destructive water evaporation.Because the existence of water can improve the efficient of melt-shaping technology, can reduce the peak value treatment temperature.Reduce the peak value treatment temperature and also further reduce heat leak, cause littler warp thus.Preferably the water yield accounts for about 0.1%～0.4% percentage by weight of paper web material.For the water of preferred amounts is provided in web surface, can increases, remove humidity or both all can.In some cases, dry paper web before embossing.In other cases, paper web can be carried out the surface water processing before embossing.In other cases, also then before embossing, use the pre-dry paper web of water treatment, carry out surface treatment for paper web by at first dry paper web.
Understand equally,, can also use other glidant although water is preferred material.Other glidant comprise with suitable amount be applied on the web surface or with web surface be shaped whole plasticizer, resin emulsion and interleaving agent.Preferred glidant can comprise one or more compounds, and this compound is selected from the chemical race of fatty acid ester and aliphatic acid.Preferred glidant comprises fatty acid ester, pentaerythritol tetrastearate.Glidant can be fed to by suitable mode on the paper web, for example dipping, coating, injection, tiny fog, absorb, be immersed in the bath of adding wetting agent, steam chamber, add in the initial plastic resin, to add initial extruding raw material to medium.Glidant preferably applies as follows, and uniform material coating promptly is provided on the paper web material surface.Preferably glidant provides and is applicable in the melt-shaping process and temporarily reduces the performance of effective picture size material Tf and/or because the condition of handling causes permanent increase web surface Tg.
In order to realize preferred temperature curve at the paper web shaping, the roller or the drum that form crush-zone can be adjusted its heat transfer performance, so that be enough to keep the suitable heating and cooling at paper web/pressing mold interface, for example active or passive heating or cooling.With reference to figure 4, roller 20 and 22 can be thermal conductivity and be provided with outer 21 and insulating barrier 23 (difference), this layer is chosen to that enough thermal insulations are only arranged, when pressing mold 14 separates with paper web 12, make web surface be cooled to it below melt-flow temperature (Tf), but do not need to be lower than its glass transition temperature (Tg).If outer 21 and insulating barrier 23 excessively insulate, web surface can not fully cool off in case when pressing mold 14 separates with paper web complete stability, make micro-structural change shape.If outer 21 or insulating barrier 23 be in insulation, pressing mold 14 can cool off a lot, and it was shunk before disengaging with paper web, causes the distortion with the path shape of smearing of micro-structural.
At the preferred embodiment of the method for the polymerization paper web material that is used for being shaped, paper web is also heating with the local opposite sidepiece that forms micro-structural, for example in " blank side ".Heating on the paper web " blank side " can be offset the residual warp power from the post annealed cooling.Can provide heat for blank side by any suitable heater.Heat preferably provides by radiant heat or is provided on the paper web by warm-up mill, and warm-up mill is configured to offset the heat penetration that is caused by the pressing mold contact.The blank side of paper web can heat before entering the processing crush-zone, for example by radiant heat or conduction heat, or heated in micro-structure forming in handling crush-zone.Blank side preferably fully heats so that the subsurface annealing that the balance die-side produces.The same way as that blank side can also add hot-die heats, and for example passes through eddy-current heating.This method is extended so that realize the melt-shaping of paper web both sides simultaneously.
In fact, the paper web material can be transported to crush-zone by any suitable paper web feeding mechanism.The device that is used to supply preferably is fit to the device along paper web path continuous transport of web material material to pressing mold, for example sheet material feeding mechanism, folding material feeding mechanism, roll-type feeding mechanism, paper web extrusion molding apparatus etc.The paper web feeding mechanism is the roll-type feeding mechanism preferably, the device shown in 300 among Fig. 5 and 9 for example, and the polymerization paper web reels of material that it is used for making in advance is fed to crush-zone.Polymerization paper web reels of material preferably includes removable material membrane or protective layer, for example the softer plastic membranous layer on the paper web.Have paper web than soft protective layer by use, paper web can roll, launches and roll, and there is seldom or does not have scratch on the surface, otherwise scratch can influence the use of the paper web that is used for the optical memory device.
The paper web feeding mechanism can be realized by the paper web pick device of for example pick-up roller, so that collect paper web after handling or being shaped.As substituting of pick-up roller, paper web can be cut into portion's section (as described below) or can further be processed into the optical memory dish of finished product or half product after being shaped.
The paper web former preferably is suitable for adjusting the variation in the paper web tension force, make paper web neither stretch tight tension only in lax.Stretch tight to such an extent that the paper web of tension can cause the paper web fracture, and too lax paper web can cause and block or other problems.In addition, the control of the tension force in the crush-zone should be controlled to the displacement of reduction subsurface material and the ellipticity of copying pattern.In order to adjust the variation in the paper web tension force, system can be provided with one or more idler rollers.Idler roller is known in the material processed operation usually, and can be used for controlling paper web speed and tension force.
Can be on the crush-zone, control tension force on extruding feed place, extruding and discharging place and the whole system.The tension force at extruding feed place preferably arrives neutral near 0.
This system also can have one or more guide roller (not shown) in case on the paper web path direct web material, thereby change the angle of paper web turnover crush-zone and change the direction of paper web.Preferably, there are at least one guide roller and/or idler roller to leave crush-zone to be used for the direct web material.These guide rollers and/or idler roller can be used for other purpose, promptly set up the separately angle of handling between crush-zone pan feeding and discharging contact and paper web and the pressing mold.Leaving guide roller on crush-zone one side, preferably to make initial paper web/pressing mold separate angle be about 90 ° ± 1 °.The direct web material left pressing mold at once after guide roller was preferably in and discharges crush-zone.
With reference to figure 1,2 and 4, the pressing mold 14 of heating is carried to crush-zone 16 by supporting member 28.Because free floating is by crush-zone, pressing mold 14 preferably is laminated on the paper web 12.Supporting member 28 preferably is independent of compression roller 20 and 22 and any parts, perhaps can disassemble from these parts.The independence of supporting member 28 makes in crush-zone 16 pressing mold 14 become at it and roughly freely floats on paper web 12 when temporarily being laminated on the paper web.By the separate support part tie layer is pressed on the paper web, can realizes that pressing mold has more than one freedom of motion and more preferably has plural freedom of motion.By having the more than one free degree, pressing mold 14 can be adjusted better and be corresponding with the moment of torsion of roller pressure generation during the melt-shaping process, and adapts to paper web texture and varied in thickness more completely.
With reference now to Fig. 2,, the formation system according to the preferred embodiment of the present invention is wherein described, this system comprises paper web former 10, this equipment has and reduces the special supports that pressing mold enters the angle of crush-zone 16.This system comprise paper web feeding mechanism 42, the paper web path 44 that is communicated with paper web feeding mechanism 42 and be arranged in paper web path 44 and pressing mold 14 in extrusion or crush-zone 16.Pressing mold 14 is by one group " endless belt " 118,128 carryings, and endless belt forms follows the supporting member that paper web path 44 is passed through crush-zone 16 and carry pressing mold 14 between pressure roll 20 and backing roll 22.Supporting member preferably can disassemble from pressure roll 20 and backing roll 22, and preferably causes in crush-zone 16 pressing mold 14 temporarily is laminated on the surface of paper web 12.As shown in the figure, endless belt is formed for the support 114 that pressing mold travels in the above.Support 114 provides the device of independent carrying pressing mold by crush-zone 16.Enter and by crush-zone, can provide the heat configuration of processing better by independent carrying pressing mold 14.In addition, by crush-zone, almost the level land keeps pressing mold by independent carrying pressing mold 14, reduces the ellipticity that curved stamp caused that shaping has the shape of minor diameter carrier drum thus.
As shown in the figure, support 114 is bearing on a plurality of rollers 30,32,34 around backing roll 22.Roller 30,32,34 makes guide rail 118,128 freely rotate.Pressing mold 14 can be connected between the guide rail 118,128 and passes through guide rail support by any proper device.Guide rail preferably separates the identical distance of width (crossing paper web) with backing roll 20, makes and has only pressing mold (relative with guide rail) to contact backing roll during operation.Guide rail 118,128 preferably has remarkable periphery greater than backing roll 22 peripheries.The ratio of guide rail and backing roll periphery is preferably at least 5: 4, and more preferably 13: 8 or bigger ratio.Guide rail with big periphery can help to keep pressing mold straightly by crush-zone 16.
In operation, backing roll 22 engages so that the guiding pressing mold contacts with paper web 2 with the rear portion of pressing mold 14, and pressure roll 20 presses the front portion that breadth is expected pressing mold simultaneously.The roller surface is advantageously selected to provides required contact uniformity, makes crush-zone dynamic shape optimization and equalizing pressure distribute, so that reduce overall pattern deformation.Pressure roll and/or backing roll preferably include flexible surface.Have the pressure roll of flexible surface and/or backing roll and can be that thereby pressing mold provides enough flexibilities improves pattern-forming so that adapt to the paper web varied in thickness.Submissive material thickness preferably between 0.05 and 0.5 inch, and more preferably about 0.125 ± 0.1 inch thick.Submissive material 21 preferably is chosen to have less than the hardness level of 80 Shore D and preferably between 90 Shore A and 60 Shore D hardness.Backing roll 22 also can comprise the layer of submissive material 23, this material can with the submissive material of pressure roll identical or different (thickness, compliance, elasticity, lubricity and/or heat conductivility).If two rollers have flexible surface, this surface preferably is adjusted to and makes comprehensive performance build-up of pressure and heat conduction uniformity optimization and not build-up of pressure, shearing and/or speed instability in pressing mold/paper web laminate.Preferred submissive material includes but is not limited to nitrile, EPDM (ethylene propylene diene rubber), Kapton (polyimides), epoxides, ring type filling oxide, Teflon (polytetrafluoroethylene (PTFE)) and injects polymer, metal or the ceramic matrix of Teflon.Understand also to use to be used for melt-shaping optical memory micro-structural and to have submissive and any material heat conductivility that its radial deflection is less than ± 0.8 degree, and tangential skew is less than ± 0.3 degree.
With reference to figure 5, the preferred embodiment of the system of optical memory medium 200 is made in its expression.System 200 comprises that paper web feeding mechanism 300, paper web material forming equipment 10, coating bringing device 400, paper web shearing device 500 and casket boxlike load or collecting apparatus 600.System 200 can be used to handle continuous web coverstock material 12 so that make finished product optical memory storage medium, for example CD.
As shown in Figure 5, the reel 310 of paper web material 12 provides by paper web feeding mechanism 300.The paper web material 12 that is used to make the optical memory substrate can have any width and thickness.Reel 310 is installed on the spool that is included in the feeding mechanism 300 interchangeably.The paper web material 12 that distributes from reel 310 can arrive former 10 through one or more guide roller/idler rollers 330.
Owing to a plurality of embodiment of substrate former have been described in front, have understood that any embodiment of the paper web former of having described can use system 200 described herein.Former 10 receives the paper web material from paper web feeding mechanism 300.Dish substrate former 10 is used for microstructure graph is formed on the paper web material.After micro-structure forming was on the paper web material, material can further be handled so that finish the manufacturing of optical memory device fully.In order further to handle the paper web material, material can be transported to coating bringing device 400.
For the paper web of blocking into before the paper web material band, multiple coating can be applied on the paper web material in a continuous manner, or after blocking coating in batch.Coating bringing device 400 can comprise one or more coated elements 410,412 etc., and this unit is used for coating is applied on the paper web 12.Coated elements can keep vacuum and use one or more coating processes to apply coating around paper web 12, for example CVD, PVD, PCVD, PECVD, PML, LML, sputter or other deposition process.
Following table 1 expression can be used to exemplary method, coating and the coating layer thickness of the required coating of shaping on phase transformation, optical memory substrate.
Table 1
| The coating step | Method | Coating | Thickness (nm) | |
| 1 | Microwave PECVD | Dielectric anti-reflective | 60～150 | |
| 2 | | Chalkogenide | 20～25 | |
| 3 | | Dielectric | 20～25 | |
| 4 | Sputter | Aluminium | 60～150 | |
| 5 | PML/LML | Acrylate | 5000～7000 |
Although can use the deposition process of any kind to apply the dielectric anti-reflective layer, in a preferred embodiment, use microwave PECVD method.The example and the system that can be used for the microwave PECVD method of coating comprise U.S. Patent number 5,411,591; 5,562,776; 5,567,241; 5,670,224; 6,186,090 and 6,209,482 described methods, wherein each patent is hereby expressly incorporated by reference.Compare with other deposition techniques, the microwave PECVD method of describing in for example above referenced patent is preferred, and this is because the speed that deposition is carried out.The deposition velocity increase can make that also the overall length of the deposition chambers that coating is required reduces.The reducing of deposition chambers length can reduce the cost relevant with deposition process greatly.
Memory layer coated elements 412 can be used to apply the phase-change memory material coating.The storage material coating preferably includes the chalcogenide alloy of about 4～30 nano thickness scopes, and more preferably is about 20～25 nano thickness.Although can use the deposition process of any kind to apply the chalcogenide alloy coating, it is to be splashed on the paper web 12 in a preferred embodiment.
Can use the second dielectric coat unit 414 to apply second dielectric coat of about 150～2000 dust thickness ranges and more preferably about 20～25 nano thickness.Suitable dielectric material comprise described those.Although can use the deposition process of any kind to apply second dielectric layer, in a preferred embodiment, use microwave PECVD method.
The coated elements 416 that is used for deposition of reflective or heat sink material can be used to apply the thin metal layer of aluminium for example or analog to substrate, and coating layer thickness is in about 1～1000 nanometer range, and more preferably about 60～150 nano thickness.Although can use the deposition process of any kind to apply any suitable material coating, in a preferred embodiment, reflection or heat dissipating layer are that sputter or evaporation are on paper web 12.
Coated elements 418 can be used to apply protective finish.Protective finish is preferably after 1000～7000 nanometers.Protective finish can be made by any suitable light transmissive material, for example thermosetting resin, uv resin, acrylate etc.In a preferred embodiment, use polymer multi-layer or liquid multi-layer (PML/LML) method that acrylate coatings is provided.The PML method relate to by modes such as extrusion molding, gravure roll, sprinkling for example with the direct vacuum coating of monomer liquid on substrate, and the monomer in the thin liquid coating of crosslinking with radiation subsequently.The LML method can need to surpass 10 microns coating, and therefore for the shaping acrylate coatings, PML can be preferred.
Each coated elements 410,418 equal vacuum chamber each other, be shaped and the isolation of feeding mechanism can realize by any suitable spacer assembly valve etc. for example with paper web.
Being used for the material of two dielectric coats and the thickness of two dielectric coats should carefully select so that realize many functions of finished product CD.These dielectric coats can protect the phase transformation coating not to be exposed under oxygen or the steam, and the oxidable phase-change material of oxygen or steam also changes its performance.Dielectric coat the contrast that provides also is provided and helps to be absorbed in the laser beam of " writing " on the dish in the phase transformation coating.Dielectric layer also can influence the hot property of CD.Second dielectric coat between phase transformation coating and the aluminized coating is chosen to enough heat conduction so that prevent that the laser eyepiece zone of phase transformation coating is overheated, but inexcessive heat conduction makes too much heat loss in aluminized coating.At last, dielectric coat provides rigid support for the phase-change material that is clipped in wherein when LASER HEATING.
Understand that the described microwave PECVD method that is used to apply dielectric coat can make dielectric material pile up on lens, these lens are with microwave source and PECVD chamber isolation.In order to help continuous web lining technology, developed the novel method that replaces lens in a continuous manner effectively.
With reference to figure 6, the material roll lining 12 that is used to make CD carries out coating by the materials in the deposition chambers 440 of coated elements 410.Deposition chambers 440 comprises opening 442.But the spool of polyester can be used to protect lens between microwave source 430 and the deposition chambers 440 to spool paper web 420 and other flexible microwave permeable materials.Microwave can see through paper web and can extract out from first spool 422 continuously or discontinuously, by opening 442 and on second spool 424.The cross-shaped portion place that opposed roller 426 or other devices can be arranged in opening 442 and polyester paper web 420 produces sealing.Polyester paper web 420 before and after PECVD operating period by opening 442 and reel repeatedly, up to the material (for example dielectric coat material) on the surface 421 run up to need to change till.Use polyester paper web 420 so that provide the microwave " window " that enters deposition chambers 440 can increase the life-span of window widely.
Above description for the coating that forms phase transformation optical memory storage device is exemplary.Understand that coat system can be used to apply any amount of different coating with different order and different-thickness, so that the wide optical memory storage device of generation scope, for example those described in the background technology of this application.Therefore, the detailed description of phase-changing storage device should not limit the scope of the invention.
Refer again to Fig. 5, after coating, paper web 12 is discharged coating bringing device 400 and is entered paper web and cuts off or cutting device 500.Paper web shearing device 500 can be any device that is fit to paper web is divided into portion's section or bar 510 (a plurality of dishes that promptly have different in width or length).The paper web shearing device can comprise the rotary cutter that is used to block paper web.The paper web shearing device also can comprise dust or the system of fragment, for example ionic air and the vacuum that is used to remove by the cutter generation.
After being with 510 shapings, their are collected or are accumulated in the tube or dismountable casket box 610 with collecting apparatus 600.By dish is collected in the integrator, can increase linear velocity and by in dismountable casket box, collecting web section, but web section off-line or on many lines, finish.Also can or directly finish the last processing of dish by the continuous reel of embossing and coating material by paper web.
The last processing of dish need accurately be shaped for the outside (overall diameter o.d) and the middle body (interior diameter i.d) that duplicate substrate and dish micro-structural.The last processing of dish can comprise any multiple operation, the method for for example punching press, cutting, milling or other shaping dish internal diameters and external diameter.
With reference to figure 7, it is represented according to the last system of processing 800 of the dish of the preferred embodiment of the present invention.Coiling last system of processing can be fit to receive and be with 510 from collecting apparatus 610.The dish last system of processing beginning, paper web be with 510 from the casket box, to be unloaded to conveyer.Band can be transported to rough cut or butt piece station 820.At butt piece station, can be cut into littler shape with 510, for example only contain the square 822 of single disc micro-structural, square then is transported to separator annular embossing station 830, the edge (promptly coiling the separator ring) of the rising of the backing material that wherein can be shaped.The separator ring makes stacked dish be convenient to when stacking together separately and prevents to damage micro-structural.After the shaping separator ring, each substrate can be transported to centre bore punching press or die-cut station 840 on the dish substrate, and then removes station 850 to waste material (material that dish is outside).After the waste material around centre bore and the dish was removed, independent semi-finished product dish can be stacked in and stack 852 places, station.
With reference to figure 8, to describe preferred paper web here and block the station, it comprises the device 842 to the microstructure graph of mid-game substrate.Device 842 can comprise platform or platform 844, and it is arranged in the top of paper web 12, has been formed with dish substrate microstructure graph 13 in paper web 12.Platform 844 can be by the translation in the x and y direction selectively of motor-driven assembly (not shown).Optical sensor 846 can and point to paper web 12 orthogonally by the platform supporting.Optical sensor 846 can provide detection signal to control module 848.The detection signal that control module 848 receives can be used to the centering and the translation of console 844.Platform 844 translations make each optical sensor 846 be located immediately at the top, edge of the microstructure graph 13 on the dish substrate.Centre bore (internal diameter) and/or (external diameter) of storage arrangement in case platform 844 centering above microstructure graph, the punching units 860 of platform 844 central authorities carrying can be used to be shaped.
The preferred embodiment of punching unit is represented with 860 in Fig. 9.Punching unit 860 can comprise stairstepping central authorities punch die 862, silicagel pad 864, spring 866 and punch die die cavity 868.Punch die can be by any suitable material structure.Punch die can comprise one or more ladders.Preferably, each ladder has the degree of depth that is fit to pierce through neatly polymer substrate.Spring 866 can be arranged to the biased downward pad so that paper web 12 is clamped between pad 864 and the punch die die cavity 868.Stairstepping punch die 862 can then press down by paper web 12 so that be shaped centre bore therein.The ladder that is formed in the center punch die 862 can reduce the possibility that centre bore has sawtooth or broken edge.
With reference now to Figure 10,, Figure 10 is used to be shaped the other embodiment of system of optical memory 200, and wherein identical reference number is represented other similar elements shown in the drawings.As shown in figure 10, paper web feeding mechanism 300 can comprise butt joint unit 340 so that supply continuous paper web by a plurality of reels 310 of paper web material.
The system that Figure 10 schematically illustrates can be used in particular in the manufacturing of dvd pickup substrate.As mentioned above, DVD makes by two dishes are bonded together.The surface that is bonded in the dish of the carrying information on the relative dish is the same surface that is applied with one or more coatings on it.But coating is unfavorable at the carrying information dish and forms the bonding of mechanically stable and tight seal relatively between the dish.Therefore, need on the dish of carrying information, leave not coating layer portion (i.e. Zhou Bian outward flange and inner rim).Therefore, the system that is used for covering a substrate part before coating can be used to be shaped and has the dish substrate of the outside and interior zone of coating not, and this zone is useful in bonding storage arrangement.
According to the preferred embodiment of the system that is used for before coating, covering a substrate part, provide a kind of indexing mechanism to make to be shaped exactly the edge of storage arrangement.The calibration of substrate can provide by one or more punching presses in advance and postorder stamping station, among Figure 10 respectively label be 900 and 950.Calibration makes the dismounting of dish and the accumulation and the coating of paper web material carry out exactly.
For example, Figure 11 indicating panel 13 is at different shaping stage A, and B, C and D, its indicating panel substrate are gradually by different treating stations.In stage A, stamping station 900 (Figure 10) can be made centre bore 15 and one or more mating holes 17 on paper web in advance.Centre bore 15 can be shaped punching unit for example shown in Figure 9 by any ways such as fusing, drilling, cuttings.Centre bore 15 can have and is same as or less than the diameter of the final center-hole diameter of finished product CD.If the diameter of centre bore 15 is during less than finished product CD required diameter, can be afterwards the processing stage in its expansion.Similar with centre bore 15, mating holes 17 can be shaped by any way, for example gear teeth punching press.Mating holes can or cannot wholely extend through paper web 12.Be that centre bore 15 and each mating holes 17 be the interval same distance exactly, makes that the relation of mating holes and centre bore is known at last.
Continuation is with reference to stage A, and after centre bore 15 and mating holes 17 were shaped in paper web 12, paper web arrived paper web former 10.Former 10 can be equipped the device that engages with mating holes 17, for example latch or key.By engaging with mating holes, former 10 can be aimed at pressing mold with paper web 12, makes microstructure graph center on centre bore 15 and locatees exactly.
With reference to the stage B of Figure 11, after microstructure graph was formed on the paper web 12, dish substrate 13 was transported to postorder stamping station 950 (Figure 10).In postorder stamping station 950, central plug 952 can be inserted centre bore 15.Central plug 952 can be made by any suitable material.Central plug 952 can be fastened on the dish substrate 13 by any suitable mode.Central plug 952 makes it cover the inner rim zone 954 of dish substrate 19 greater than centre bore 15.The inner rim zone 954 of covering preferably is fixed into has the roughly width of traditional sucrose width.
With reference to the stage C of Figure 11, outer covering 956 covers on the dish substrate 13, and substrate is positioned on the postorder stamping station 950 simultaneously.Outer covering 956 can be aimed at paper web 12 by engaging with the mating holes 17 of paper web to come.Outer covering 856 can be made by any suitable material.Outer covering 956 can be fastened on the dish substrate 13 in any suitable manner.The diameter of the inner opening 957 of outer covering 956 makes the periphery area 958 of its covering disk substrate less than the final diameter of dish substrate 13.The periphery area 958 that covers preferably has the width of about 1/2～3mm, and the about width of 1mm more preferably.
After connector 952 and outer covering 956 were in place, dish substrate 13 can be transported to paper web shearing device 500 from postorder stamping station 950, located at this, and what paper web 12 can cut into suitable length and/or width is with 510.Be with 510 can accumulate so that further batch processing or horse back are transported to coating bringing device 400.At coating bringing device 400 places, band can be placed on along in the track of the interior cylindrical surface layout of barrel tumbler part 450.Being with 510, can be loaded into drum inner or be coated with in the laminar flow.Drum can seal by appropriate device in coating procedure.
The drum 450 of coating bringing device 400 can be arranged to perpendicular to paper web 12 suppliers to rotation.To rouse perpendicular to the paper web supplier makes breadth strip 510 direct linear travel in drum 450 to layout.But the sidepiece opening relative with paper web shearing device 500 of drum 450 is so that make one or more coated elements 410 insert wherein.Coated elements 410 can be installed on the inwall that can be sealed in the drum 450.In case the wall closure of coated elements 410 is installed, drum can rotate around its axis, and the breadth strip 510 that makes edge drum inwall arrange is carried the different coating zone that limits by by coated elements 410.Figure 12 represents drum 450 and limits the side view of deposition chambers 440 wherein.Handle in order to adopt cydariform coating apparatus 400 to carry out coating, can drum cooler 450 or the interior substrate of drum.The method of drum cooler 450 is the outer setting water jackets around drum.The temperature of using water jacket can control drum and be arranged in the inner breadth strip of drum.
Continuation after dish substrate 13 coatings, is removed connector 952 and outer covering 956 with reference to Figure 11.Dish substrate 13 then appears at stage D, and it is included in coating on the surface outside periphery area 958 and the inner rim zone 954.The breadth strip that arrives stage D then is transported to last processing line, for example in conjunction with described one of Fig. 7.But, the last processing station that is used to arrive the dish substrate of stage D can need other station in case with the substrate binding of carrying information at substrate (for example material of blank or embossing) relatively.
Another embodiment of cydariform coating apparatus 400 be make coating apparatus 400 according to the paper web supplier to rotation.Therefore, the dish substrate of band or paper web form can directly be loaded on the drum 450 when drum rotates.
The embodiments of the invention of Pi Luing can use or not use melt-shaping before this.Though melt-shaping can be in the very short time cycle (grade of tens microseconds is preferably littler) with micro-structure forming on web surface, a plurality of embodiment of this method can be used for other reproduction process.Though describe the present invention in detail in accompanying drawing and above explanation, and explanation is thought and do not limit the present invention in itself exemplary, the notion here is applicable to any shapable material.Those skilled in the art will appreciate that the present invention can carry out modification and remodeling and do not depart from scope of the present invention or spirit.For example, can change the size of optical substrate and be shaped wherein micro-structural and do not depart from scope of the present invention or spirit.The material that is used to construct the different elements (for example pressure and backing roll, pressing mold, pressing mold supporting member and heater) that the embodiment of the invention uses be can change and scope of the present invention or spirit do not departed from.In addition, understand that the supporting member and the backing roll that are used for pressing mold can combine so that overall structure is provided.Pressing mold can then separate with the backing roll that has insulator.Secondly, understand that the present invention may extend among the embodiment that uses any type of optical memory substrate, for example paper web, sheet material or other forms.Moreover, by with combination or separately use described one or more embodiment, by 1.2mm or littler paper web material, can produce radial deflection less than ± 0.8 degree, the tangential optical memory dish that is offset less than ± 0.3 degree, wherein birefringence is less than the 100nm round trip, more preferably less than the 90nm round trip, and more preferably less than 60nm radiation round trip.Therefore, the present invention is intended to cover all these modification and remodeling, and these modification and remodeling are positioned at the scope of claims and equivalent thereof.
Claims (19)
1. one kind forms the equipment of micro-structural for use in optical memory on the surface of polymeric material paper web, and it comprises:
Paper web feeding mechanism (42);
Be used for the device that paper web is shaped, the device that is used for the paper web shaping has pressing mold (14) and pair of rolls (20,22), roller forms the crush-zone that is communicated with the paper web feeding mechanism, described pressing mold is by passing crush-zone from the supporting member carrying of roller dismounting, described supporting member comprises mutual at least two endless belt (118 that are arranged that axially divide, 128), described pressing mold is positioned at the supporting member between described two endless belt, the part of wherein said pressing mold graft polymerization thing material roll lining in crush-zone.
2. equipment as claimed in claim 1 is characterized in that, a roller in the described pair of rolls is the backing roll that is used for pressing mold is pressed into paper web, and the periphery of endless belt is bigger than the periphery of backing roll.
3. equipment as claimed in claim 2 is characterized in that, the ratio of the periphery of each endless belt and backing roll periphery is 5: 4 at least.
4. equipment as claimed in claim 2 is characterized in that, the ratio of the periphery of each endless belt and backing roll periphery is 13: 8 at least.
5. equipment as claimed in claim 1 is characterized in that paper web comprises the surf zone that has glidant.
6. equipment as claimed in claim 5 is characterized in that, glidant is 0.1%～0.4% percentage by weight that the water yield accounts for the paper web material.
7. equipment as claimed in claim 6 is characterized in that, the degree of depth of water from this surface to 10 μ m is provided with.
8. equipment as claimed in claim 6 is characterized in that water is provided with from the surface to the degree of depth of 3 μ m.
9. equipment as claimed in claim 6 is characterized in that water is provided with from the surface to the degree of depth of 1.5 μ m.
10. equipment as claimed in claim 6 is characterized in that water is provided with from the surface to the degree of depth of at least 0.003 μ m.
11. equipment as claimed in claim 1 is characterized in that, described pressing mold is to be heated.
12. equipment as claimed in claim 11 is characterized in that, described pressing mold is sensed heating.
13. equipment as claimed in claim 1 is characterized in that, at least one roller in the described pair of rolls is to be heated.
14. equipment as claimed in claim 1 is characterized in that, described pressing mold is a curved stamp.
15. equipment as claimed in claim 1 is characterized in that, be 300 milliseconds or littler joint time of contact between the described part of pressing mold and paper web.
16. equipment as claimed in claim 1 is characterized in that, be 20 milliseconds or littler joint time of contact between the described part of pressing mold and paper web.
17. equipment as claimed in claim 1 is characterized in that, be 10 milliseconds or littler joint time of contact between the described part of pressing mold and paper web, but greater than 0.5 millisecond.
18. equipment as claimed in claim 1 is characterized in that, at least one roller in the described pair of rolls comprises flexible surface.
19. equipment as claimed in claim 18, it is characterized in that described flexible surface is included as the material of polymer, metal or the ceramic matrix of nitrile, ethylene propylene diene rubber, polyimides, epoxides, ring type filling oxide, polytetrafluoroethylene (PTFE) and injection polytetrafluoroethylene (PTFE).
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| PCT/US2002/020530 WO2004002708A1 (en) | 2001-06-26 | 2002-06-26 | Method and apparatus for forming microstructures on polymeric substrates |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN1547523A CN1547523A (en) | 2004-11-17 |
| CN100418724C true CN100418724C (en) | 2008-09-17 |
Family
ID=34271581
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CNB028167252A Expired - Fee Related CN100418724C (en) | 2002-06-26 | 2002-06-26 | Method and equipment for forming microstructure on polymer substrate |
Country Status (3)
| Country | Link |
|---|---|
| JP (1) | JP2005531098A (en) |
| CN (1) | CN100418724C (en) |
| AU (1) | AU2002345966A1 (en) |
Families Citing this family (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2008026277A1 (en) * | 2006-08-31 | 2008-03-06 | Bridgestone Corporation | Method for producing photo-curing transfer disc sheet suitable for production of optical information recording medium, and photo-curing transfer disc sheet produced by that method |
| JP5751751B2 (en) * | 2009-12-25 | 2015-07-22 | 三菱重工業株式会社 | Reinforcing fiber substrate laminating apparatus and laminating method |
| US11701683B2 (en) | 2010-12-22 | 2023-07-18 | The Procter & Gamble Company | Methods for foil stamping parts having asymmetrical edges |
| CA2822395C (en) * | 2010-12-22 | 2015-05-12 | The Procter & Gamble Company | Methods for foil stamping parts having asymmetrical edges |
| CN102744902B (en) * | 2012-05-07 | 2015-01-21 | 罗凯 | Soft and hard roller continuous cyclic bending method and device |
| CN103433280B (en) * | 2013-07-18 | 2016-02-24 | 浙江中隧桥波形钢腹板有限公司 | Self comsuming pressing mold composite equipment and technique |
| CN108515688B (en) * | 2018-04-11 | 2020-07-28 | 王君豪 | Preparation method of super-hydrophobic plastic film |
| CN110031330B (en) * | 2019-03-07 | 2022-03-08 | 航天科工防御技术研究试验中心 | Test sample for bonding strength of ceramic coating, preparation method and test method |
| CN113263729B (en) * | 2021-07-16 | 2021-10-08 | 广东天安新材料股份有限公司 | Lamination method of multilayer polyvinyl chloride film |
| CN114474540B (en) * | 2022-02-10 | 2022-11-25 | 广州海天塑胶有限公司 | Plastic punch forming HSM (high speed Metal Molding) process for plastic accessory processing |
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| US4223050A (en) * | 1976-05-04 | 1980-09-16 | Lgz Landis & Gyr Zug Ag | Process for embossing a relief pattern into a thermoplastic information carrier |
| US4486363A (en) * | 1982-09-30 | 1984-12-04 | Amerace Corporation | Method and apparatus for embossing a precision optical pattern in a resinous sheet |
| US5053252A (en) * | 1988-08-03 | 1991-10-01 | Sharp Kabushiki Kaisha | Method and apparatus for manufacturing optical memory devices |
| US5447676A (en) * | 1992-10-19 | 1995-09-05 | Takeda Chemical Industries, Ltd. | Low-pressure and low-temperature moldable composition and shaped article therefrom |
| US5827584A (en) * | 1994-10-27 | 1998-10-27 | Fuji Photo Film Co., Ltd. | Injection molded article for photographic photosensitive material, molding method thereof and package using the same |
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| JPH0276728A (en) * | 1988-09-13 | 1990-03-16 | Canon Inc | Manufacture of base for optical information recording medium |
| JPH02182433A (en) * | 1989-01-09 | 1990-07-17 | Toppan Printing Co Ltd | Preparation of optical recording medium |
| JPH03230334A (en) * | 1990-02-02 | 1991-10-14 | Sharp Corp | Method and apparatus for manufacturing of substrate for optical medium |
| JPH03241542A (en) * | 1990-02-19 | 1991-10-28 | Fuji Photo Film Co Ltd | Automatic punching method for flexible optical disk |
| JPH04147446A (en) * | 1990-10-09 | 1992-05-20 | Ube Ind Ltd | Manufacture of optical medium |
| JPH0676356A (en) * | 1992-06-19 | 1994-03-18 | Canon Inc | Optical recording medium, substrate for optical recording medium, and productio of substrate for optical recording medium |
| JPH06195757A (en) * | 1992-12-21 | 1994-07-15 | Toppan Printing Co Ltd | Manufacture of optical recording medium |
| JP2800908B2 (en) * | 1993-05-13 | 1998-09-21 | 日本製紙 株式会社 | Calendar processing method for paper sheet |
| JPH0714220A (en) * | 1993-06-24 | 1995-01-17 | Canon Inc | Forming roll of substrate sheet for optical recording medium |
| JPH08147772A (en) * | 1994-11-25 | 1996-06-07 | Canon Inc | Roll for producing optical recording medium |
| JPH08161775A (en) * | 1994-11-30 | 1996-06-21 | Canon Inc | Stamper for manufacture of optical recording medium |
| JPH0922545A (en) * | 1995-07-03 | 1997-01-21 | Canon Inc | Manufacture of substrate for optical recording medium |
| JPH11345436A (en) * | 1998-06-01 | 1999-12-14 | Sony Corp | Production of optical recording medium and apparatus for manufacturing optical recording medium |
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2002
- 2002-06-26 JP JP2004517480A patent/JP2005531098A/en active Pending
- 2002-06-26 CN CNB028167252A patent/CN100418724C/en not_active Expired - Fee Related
- 2002-06-26 AU AU2002345966A patent/AU2002345966A1/en not_active Abandoned
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4223050A (en) * | 1976-05-04 | 1980-09-16 | Lgz Landis & Gyr Zug Ag | Process for embossing a relief pattern into a thermoplastic information carrier |
| US4486363A (en) * | 1982-09-30 | 1984-12-04 | Amerace Corporation | Method and apparatus for embossing a precision optical pattern in a resinous sheet |
| US5053252A (en) * | 1988-08-03 | 1991-10-01 | Sharp Kabushiki Kaisha | Method and apparatus for manufacturing optical memory devices |
| US5447676A (en) * | 1992-10-19 | 1995-09-05 | Takeda Chemical Industries, Ltd. | Low-pressure and low-temperature moldable composition and shaped article therefrom |
| US5827584A (en) * | 1994-10-27 | 1998-10-27 | Fuji Photo Film Co., Ltd. | Injection molded article for photographic photosensitive material, molding method thereof and package using the same |
Also Published As
| Publication number | Publication date |
|---|---|
| JP2005531098A (en) | 2005-10-13 |
| AU2002345966A1 (en) | 2004-01-19 |
| CN1547523A (en) | 2004-11-17 |
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